Plural nested preform assembly and method of manufacture

ABSTRACT

A plural preform assembly having nested preforms. The preforms are held together by an interference fit. The interference fit is provided by the friction between the preforms which occurs when the inner preform is inserted into the outer preform. At least one preform may have ribs extending radially towards the other preform. The ribs provided concentricity and interference to hold the preforms together during subsequent operations. The preforms may later be blow molded to provide a bag in bottle or similar container.

FIELD OF THE INVENTION

The present invention relates to preforms for plastic containers havinga bag therein.

BACKGROUND OF THE INVENTION

Preforms are well known in the art. Preforms are typically injectionmolded. In a later operation the preform is blow molded to the finalshape, often with the assistance of a stretch rod.

Preforms may be nested, so that an inner preform is disposed within anouter preform. This arrangement provides the benefit that both preformsmay be blow molded at the same time and in a single operation. Aseparate operation to insert one preform inside another is necessary.

The two, or more, preforms may be injection molded in separateoperations, requiring assembly to nest the preforms for the single blowmolding operation. But assembly, in order to nest the preforms, mayoccur at a first location. The nested preforms may be shipped to asecond location, miles away, for warehousing or blow molding. Ifwarehoused, the nested preforms may be subjected to thermal cycling, andlikely shipped again for blow molding. In preparation for the blowmolding operation, the nested preforms may be run through a tumbler,bulk sorter and/or stacker.

But the shipping, warehousing, tumbling, sorting and/or stackingoperations may dislodge and separate the previously nested preforms. Ifthe preforms become separated, re-assembly is necessary, defeating thepurpose of nesting. Previous attempts include: US 2012/0132607, U.S.Pat. Nos. 6,499,311, 6,649,121, 8,851,322 and 9,162,372.

An aerosol container having a bag therein may be made from a dual layerpreform, having plural layers disposed one inside the other. Relevantattempts in the art include U.S. Pat. Nos. 3,450,254; 4,330,066;6,254,820; RE 30093 E; WO 9108099 and US 2011/0248035 A1. But some ofthese attempts rely upon blow molding the inner and outer preformstogether. But this operation may not be suitable if charging without abung hole is desired or tolerance stackup is to be avoided. And some ofthese attempts rely upon mechanical block of the inner preform by theshoulder of the outer preform, to prevent separation. But this geometryis not suitable if a smaller shoulder is desired.

It is necessary to join the nested preforms in a way that preventsseparation during operations which occur between nesting and blowmolding. But such joining should be simple, to overcome the problemsassociated with trying to automate joining using interlocks and similarcompound motion. This invention is directed to the problem of unintendedseparation of nested preforms.

SUMMARY OF THE INVENTION

The invention comprises a plural preform assembly. The plural preformassembly has a longitudinal axis defining a longitudinal direction andcomprises an outer preform having an outer preform open end and an outerpreform closed end longitudinally opposed thereto, an outer preformsidewall joining the outer preform open end and the outer containerclosed end, the outer preform further having an outer preform innersurface and an outer preform outer surface. The plural preform assemblyfurther comprises an inner preform disposed at least partially withinthe outer preform, the inner preform having an inner preform open endand an inner preform closed end longitudinally opposed thereto, an innerpreform sidewall joining the inner preform open end and the innerpreform closed end, the inner preform further having an inner preforminner surface and an inner preform outer surface. The inner preform andouter preform are mechanically joined at the respective open ends by aradial interference fit.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are to scale, unless otherwise noted.

FIG. 1A is a perspective view of a plural preform assembly according tothe present invention.

FIG. 1AA is a top plan view of the plural preform assembly of FIG. 1A.

FIG. 1B is a side elevational view of the plural preform assembly ofFIG. 1A.

FIG. 1C is a vertical sectional view taken along lines 1C-1C of FIG.1AA.

FIG. 1CC is an enlarged fragmentary view taken from FIG. 1C.

FIG. 1D is a vertical sectional view taken along lines 1D-1D of FIG.1AA.

FIG. 1DD is an enlarged fragmentary view taken from FIG. 1D.

FIG. 1AE is a partially exploded perspective view of a plural preformassembly according to the present invention.

FIG. 1AAE is a top plan view of the plural preform assembly of FIG. 1AE.

FIG. 1BE is a partially exploded side elevational view of the pluralpreform assembly of FIG. 1AE.

FIG. 10E is a vertical sectional view taken along lines 10E-10E of FIG.1AAE.

FIG. 1CCE is an enlarged fragmentary view taken from FIG. 10E.

FIG. 1DE is a vertical sectional view taken along lines 1DE-1DE of FIG.1AAE.

FIG. 1F is a schematic vertical sectional view, not drawn to scale, ofan exploded plural preform assembly having an intermediate preform.

FIG. 1DDE is an enlarged fragmentary view taken from FIG. 1DE.

FIG. 2A is a perspective view of the outer preform of FIG. 1A, showingfour notches not drawn to scale, otherwise FIGS. 2A-2CC being to scale.

FIG. 2AA is a top plan view of the outer preform of FIG. 2A

FIG. 2B is a side elevational view of the outer preform of FIG. 2A.

FIG. 2C is a vertical sectional view taken along lines 2C-2C of FIG.2AA.

FIG. 2CC is an enlarged fragmentary view taken from FIG. 2C.

FIG. 2D is a schematic bottom view, not drawn to scale of an outerpreform having diagonal and radial inwardly extending ribs.

FIGS. 3A1 and 3A2 are perspective views of the inner preform of FIG. 1A.

FIG. 3AA is a top plan view of the inner preform of FIG. 3A1.

FIG. 3AB is a bottom plan view of the inner preform of FIG. 3A1.

FIG. 3B is a side elevational view of the inner preform of FIG. 3A1.

FIG. 3C is a vertical sectional view taken along lines 3C-3C of FIG.3AA.

FIG. 3CC is an enlarged fragmentary view taken from FIG. 3C.

FIG. 3DD is an enlarged fragmentary view taken from FIG. 3A1.

FIG. 4A is a perspective view of an alternative embodiment of an innerpreform assembly, having plural internal preforms in parallel with acommon septum and no threads.

FIG. 4B is a perspective view of an inner preform assembly, havingplural internal preforms in parallel with symmetrically oppositepreforms in contacting relationship and no threads.

FIG. 5A is a perspective view of an inner preform having no channels andribs with plural diameters.

FIG. 5B is a side elevational view of the preform of FIG. 5A.

FIG. 5C is a bottom view of the preform of FIG. 5A, the radialdimensions of the ribs in FIGS. 5A-5C not necessarily being drawn toscale.

FIG. 6A is a side elevational view of an exemplary dispenser accordingto the present invention.

FIG. 6AA is a top plan view of the inner preform of FIG. 6A.

FIG. 6B is a vertical sectional view taken along lines 6B-6B of FIG.6AA.

FIG. 6BB is an enlarged fragmentary view taken from FIG. 6B.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1A-1F, the invention comprises a plural preformassembly (20). The plural preform assembly (20) has a plurality ofinjection molded preforms (30)(40), which are nested together. Theplural preform assembly (20) more particularly comprises an outerpreform (30) and an inner preform (40) nested therein. Optionally, oneor more intermediate preforms (96) may be interposed between the outerpreform (30) and inner preform (40). The optional intermediate preforms(96) internal to an outer preform (30) and external to an inner preform(40).

Each preform (30)(40) has a finish (34)(44) and a body (32)(42)depending therefrom. The finish (34)(44) and body (32)(42) may beintegral. The finish (34)(44) is generally not affected by subsequentmolding operations. The body (32)(42) is generally blown to attenuatewall thickness and increase both length and/or cross sectional area.

Each preform (30)(40), and the container made therefrom, has a closedend which is typically at the bottom of the preform or container.Likewise, each preform (30)(40), and the container made therefrom, hasan open end which is typically at the neck (84) of the preform (30)(40)or container.

By nested it is meant that a first preform (40) is inserted into asecond preform (30)(96), so that the finishes (34)(44) of the preforms(30)(40) are in mutual contact. The second preform (96) may be nestedinto a third preform (30), and so on. The first preform (40) may bedirectly nested into a single outer preform (30), providing a dualpreform assembly (20) within the scope of the invention. The body (42)of the first preform (40) may lightly contact or be spaced away from thebody (32) of the second preform (30)(96), so that assembly into thenested configuration can easily occur.

Preferably the body of the inner preform (42) and body of the outerpreform (32) do not touch throughout the sidewalls and/or bottoms of therespective bodies. By avoiding contact or touching, problems withtolerance stackup are avoided, as are problems with the bodies (32)(42)of the nested inner preform (40) and outer preform (30) melting togetherupon reheat during subsequent blow molding. If desired a release agentmay be applied to improve delamination of the inner preform (40) andouter preform (30) during or after the blow molding process.

Each of the inner preform (40) and outer preform (30) is blow moldedinto a respective inner container (90) and outer container (80). Theinner container (90) is blow molded from the inner preform (40) and maycontain product for later dispensing and provide a barrier againstpropellant. The outer container (80) is blow molded from the outerpreform (30), may contain propellant and provide for handling by theuser.

Such an outer container (80) may define a longitudinal axis L-L of theaerosol dispenser. The outer container (80) may be axisymmetric asshown, or, may be eccentric. While a round cross-section is shown, theinvention is not so limited. The cross-section may be square,elliptical, irregular, etc. Furthermore, the cross section may begenerally constant as shown, or may be variable. If a variablecross-section is selected, the outer container (80) may be barrelshaped, hourglass shaped, or monotonically tapered.

The outer container 22 may range from 6 to 60 cm, and particularly 10 to40 cm in height, taken in the axial direction and from 3 to 60 cm, andparticularly 4 to 10 cm in diameter if a round footprint is selected.The outer container 22 may have a volume ranging from 40 to 1000 ccexclusive of any components therein, such as a product delivery device.The outer container 22 may be injection stretch blow molded. If so, theinjection stretch blow molding process may provide an overall stretchratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15 or 20 and less than 50,40 or 30.

The inner preform (40) may be blow molded to form an inner container(90), particularly a collapsible bag (92). Such a collapsible bag (92)may hold product therein, for subsequent dispensing by a user. The innercontainer (90), upon blow molding, may have a wall thickness of 0.07 to0.3 mm, exclusive of any ribs (48) disposed thereon. The bag (92) maycomprise two layers including nylon and either EVOH or PET. Or threelayers may be utilized, including PET/Nylon/Pet or PET/EVOH/PET. Thelayers may be co-molded or overmolded. The multi-layer arrangements arebelieved to provide increased flexibility, increased barrier resistanceand reduced pinholing.

Referring to FIGS. 2A-2CC, and examining the outer preform (30) in moredetail, the outer preform (30) may have a finish. The finish of theouter preform (34) may be larger in diameter than the body. The finishmay be made according to the teachings of U.S. Pat. Nos. 6,019,252;6,971,530 (particularly FIGS. 4, 5 and 7 thereof), U.S. Pat. Nos.7,303,087 and 7,028,866.

The finish of the outer preform (34) may have an outer preform collar(36). The collar (36) defines the largest diameter of the outer preform(30), and preferably, but not necessarily, circumscribing, the perimeterof the preform (30). The outer preform collar (36), particularly theinner or upwardly facing surface thereof, provides a seat for attachmentof the finish of the inner preform (44) thereto.

If desired, the outer preform finish (34) and/or inner preform finish(44) may have a deformation band therein. The deformation band mayprovide for plastic deformation of the band upon insertion of the innerpreform (40) into the outer preform (30). The ribs (48) may plasticallyseat into the deformation band, preventing relative rotation between theinner preform (40) and outer preform (30).

The deformation band is a thin layer of material which plasticallyradially deforms under the radially outward pressure of the ribs (48)Likewise the ribs (48) may plastically deform under resistance from thedeformation band. The ribs (48) provide concentrated forces which deformonly the respective portions of the band contacted thereby. Thedeformation band may have reduced diameter relative to the balance ofthe finish of the outer preform (34).

The body of the outer preform (32) may taper inwardly as the distal end,located at the bottom of the preform, is approached. The body of theouter preform (32) may have a transition zone (37) subjacent or somewhatbelow the finish. The transition zone (37) may provide for a reductionin diameter, and particularly a monotonic reduction in diameter, betweenthe underside of the finish and the balance of the body. The transitionzone (37) may accommodate radially extending ribs (48) on either theinner preform (40) or the outer preform (30).

The collar (36) of the outer preform (30) may have one or more notches(38) therein. The notches (38) may be complementary to the ribs (48) andengage the ribs (48) of the inner preform (40). Such engagement of theribs (48) and notches (38) may reduce undesired spinning of the innerpreform (40) and outer preform (30) relative to each other during theblow molding operation.

One of skill will recognize that the notches (38) may be disposed on theinner preform (40) and ribs (48) disposed on the outer preform (30) in avariation. Or both the inner preform (40) and outer preform (30) mayhave ribs (48) which engage the other preform. In such an embodiment,either or both preforms may also have complementary notches (38) whichengage the other preform.

Referring to FIGS. 3A1-3DD, the finish (44) of the inner preform (40)may optionally be threaded. The threads (49) may be external, orpreferably internal, to the preform (40). Internal threads (49) can beused to accept a complementary valve assembly. The valve assembly formsno part of the claimed invention, except as specifically set forthherein.

The inner preform (40) may have an inner preform collar (46). The innerpreform collar (46) may be complementary to the outer preform collar(36) of the outer preform (30), so that the inner preform (40) may nestwithin the outer preform (30).

The inner preform (40) and outer preform (30) are joined together. Theinner preform (40) and outer preform (30) may be permanently joinedtogether so that separation of the nested preforms (30)(40) does notoccur without unintended damage to either the inner preform (40) orouter preform (30). Alternatively, the inner preform (40) and outerpreform (30) may be removably joined together so that the inner preform(40) and outer preform (30) can be separated, but remain nested duringordinary manufacturing, shipping and storage.

Nesting and concomitant joining of the inner preform (40) and outerpreform (30) may be accomplished with a friction fit. A friction fitoccurs due to radial interference between at least a portion of theinner preform (40) and at least a portion of the outer preform (30). Thefriction fit causes the inner preform (40) and outer preform (30) toremain in position and nested during subsequent processing, until andthrough blow molding. Blow molding occurs while the preform (30)(40) arenested, so that a bag in bottle results.

The friction fit may occur between any portion of the inner preform (40)and outer preform (30), particularly between the finish (44) of theinner preform (40) and finish (34) of the outer preform (44). Thediametrical radial interference may be less at least 0.05 mm, and lessthan 1 mm, 0.5 mm and 0.1 mm, with a diametrical fit of 0.6 mm havingbeen found suitable.

A friction fit provides the benefit that a separate material, such asadhesive, is not necessary to maintain the inner preform (40) and outerpreform (30) in the nested configuration throughout subsequentprocessing and blow molding. A friction fit also provides the benefitthat a mechanical interlock, such as a bayonet fitting or screw threadis not needed to maintain the nested configuration. A mechanicalinterlock adds to the injection molding cost and requires a separateoperation to index and join the inner preform (40) and outer preform(30). Thus, joining materials and mechanical interlocks may beadvantageously avoided and omitted with the present invention, whileretaining the advantages of nesting.

The inner preform (40) may optionally have a plurality of, preferablythree or more, outwardly extending ribs (48). The ribs (48) provide forconcentric alignment of the inner preform (40) and outer preform (30).The ribs (48) also resist unintended distortion/expansion of the innerpreform (40) if the plural preform assembly (20) is later pressurizedfor use as an aerosol dispenser.

The ribs (48) may be complementary to the transition zone (37) of theouter preform (30). Upon longitudinally inserting the inner preform (40)into the outer preform (30), the ribs (48) radially contact and engagethe inner surface of the outer preform (30). The ribs (48) may beunequally or preferably equally circumferentially spaced around thecircumference of the finish (44), with preferably the ribs (48) haveconcentric and constant maximum diameter. The preform (40) may havefrom, 4 ribs (48) to 30 ribs (48), 8 to 24 ribs (48), and particularlyfrom 12 to 20 ribs (48), more particularly 16 ribs (48), equally sizedand equally circumferentially spaced.

The ribs (48) may have a radial dimension of 2 to 8 mm, 4 to 6 mm, andparticularly 5 mm. The ribs (48) may have a thickness in thecircumferential direction of 0.5 to 1.5 mm, particularly 0.8 to 1.2 mmand more particularly 1 mm.

It is desired that the ribs (48) not have excessive thermal mass, sothat the ribs (48) do not provide undue heat sink during injectionmolding and deform or require undue thickness in the mating component.While ribs (48) of constant thickness are shown, one of skill willrecognize that the ribs (48) may taper in thickness from the proximalend to the distal end. The taper provides the unexpected benefit ofreduced contact area at the position where the ribs (48) contact theouter preform (30). The taper may also provide for some plasticdeformation, joining the inner preform (40) and outer preform (30).

In the longitudinal direction, the ribs (48) may taper inwardly,corresponding to the transition of the inner preform (40) and providingfor monotonically reduced diameter as the distal end of the innerpreform (40) is approached. The taper provides the unexpected benefit ofa funnel effect so that the inner preform (40) and outer preform (30)are concentric upon nesting.

If desired, the underside of the inner preform (40) finish and/or theupper side of the outer preform (30) may have channels (47)therethrough. The channels (47) may provide for charging the outercontainer (80) with propellant and subsequent sealing to maintainpressure. Suitable charging and sealing processes are particularlydescribed in commonly assigned U.S. Pat. No. 8,869,842 to Smith at FIG.9 and column 8, lines 30-43.

Referring to FIGS. 4A-4B, the plural preform assembly (20) may comprisea single outer preform (30) and two, or more, inner preforms (40)disposed in parallel to comprise an inner preform (40) assembly (20).Such a plural preform assembly (20) may comprise two inner preforms (40)which become respective bags (92) and are separated by a common septum(45). Or, alternatively, the plural preform assembly (20) may comprisetwo inner preforms (40) which are mirror images of each other and placedin proximate or even contacting relationship to the other.

Each of these inner preforms (40) may hold a unique product which isisolated until dispensed at the point of use. The parallel innerpreforms (40) may be equally or unequally sized and shaped, dependingupon the relative proportions of products desired to be co-dispensedtherefrom. The parallel arrangement provides the benefit that chemicallyunstable materials are not prematurely mixed, causing loss of efficacy.The products in the separate inner preforms (40) may be dispensed usinga common actuator and have separate dedicated valves or a commonmanifold to a valve. One of skill will recognize that two or moreintermediate bags (92) may be coaxially disposed. The intermediate bags(92) may be relatively rigid or relatively flexible.

Referring to FIGS. 5A-5C, an inner preform (40) having ribs (48) of atleast two different diameters is shown. A first plurality of the ribs(48) may have a first diameter. A second plurality of ribs (48) may becircumferentially interspersed with or throughout the first plurality ofribs (48) and have a second diameter less than the first diameter. Thefirst diameter is larger than the second diameter. This arrangementprovides the benefit that upon nesting, the ribs (48) having the firstdiameter provide frictional engagement, so that undesired separation ofthe preforms (30)(40) does not occur. The ribs (48) having the second,and smaller, diameter may not contact the outer preform (30) while theinner preform (40) and outer preform (30) are at ambient pressure. Butthe ribs (48) of lesser diameter advantageously provide structuralsupport in the axial direction while conserving material. Suchstructural support can minimize leakage past the valve, due todeformation which occurs under pressurization.

In such an embodiment, the nested inner preform (40) and outer preform(30) are blow molded into a respective nested inner container (90) andouter container (80), the space between the inner container (90) andouter container (80) may be charged with propellant to a positivepressure greater than ambient pressure. The positive pressure may causeradial expansion of the inner preform (40), causing engagement of theribs (48) having the second smaller diameter with the outer container(80).

Referring to FIG. 2D, the invention has been described with respect toradially outwardly extending ribs (48) disposed on the outer surface ofthe inner preform (40). One of skill will recognize that instead of, orin addition to such ribs (48) as described above, ribs (48) may also bedisposed on the inner surface of the outer preform (30). While the ribs(48) have previously been shown as being identically radially oriented,one of skill will recognize some or all of the ribs (48) may bediagonally oriented relative to the longitudinal axis and orcircumference. Likewise, the ribs (48) of the inner preform (40) may bediagonally radially oriented, instead of or in addition to identicallyradially oriented.

Referring to FIGS. 6A-6BB, dispensers having an inner container (90) andouter container (80) are well known in the art. Aerosol dispenserstypically comprise an outer container (80) which acts as a frame for theremaining components and as a pressure vessel for propellant and productcontained therein. Relevant attempts in the art to employ plastic inaerosol dispensers are found in U.S. Pat. Nos. 2,863,699; 3,333,743 and2009/0014679.

The outer container (80) has an open top which defines a neck (84) forreceiving additional components of the aerosol dispenser. The industryhas generally settled upon a diameter of 2.54 cm, for standardization ofcomponents among various manufacturers, although smaller diameters, suchas 20 mm, are also used. Typically a valve cup (94) is inserted into theopen top. The valve cup (94) is sealed against the neck (84) to preventthe escape of the propellant and loss of pressurization, such asdescribed in commonly assigned U.S. Pat. No. 8,869,842 or as describedin U.S. Pat. No. 8,096,327. The valve cup (94) holds the valvecomponents which are movable in relationship to the balance of theaerosol dispenser.

A collapsible, flexible bag (92), blow molded from the inner preform(40) may be sealed to the opening on the underside of the valve cup (94)or may be placed between the valve cup (94) and the container. This bag(92) limits or even prevents intermixing of the contents of the bag (92)and the components outside of the bag (92). Thus, product may becontained in the bag (92). Propellant may be disposed between theoutside of the bag (92) and inside of the outer container (80). Uponactuation of the valve, a flow path out of the bag (92) is created. Thisembodiment is commonly called a bag (92) on valve and may be used, forexample, in dispensing shaving cream gels, suntan lotion, hard surfacecleaners, body sprays, laundry detergents, air fresheners, astringents,foods, paint, insecticides, perfumes, foaming personal care productssuch as shampoos and deodorants, etc.

The neck (84) may be connected to the container sidewall by a shoulder(85). The shoulder (85) may more particularly be joined to the sidewallby a radius. The shoulder (85) may have an annular flat. The neck (84)may have a greater thickness at the top of the outer container (80) thanat lower portions of the neck (84) to provide a differential thickness.Such differential thickness may be accomplished through having aninternally stepped neck (84) thickness.

A valve cup (94) may be sealed to the opening of the outer container(80), as described in further detail below. The valve cup (94) may besealed to the neck (84) of the outer container (80) using the class 1TPE material. Polyester based TPE sold by Kraiburg TPE GmbH & Co KG ofWaldkraiburg, Germany under the name HTC8791-52 and by DuPont ofDelaware under the name HYTEL may be used for good resistance toSilicone and adhesion to PET. Or a styrenic block copolymer based TPEsuch as Kraiburg HTC8791-24 or Krayton elastomer may be used, providingrelatively easy processing and lower density. Other seal materialsinclude silicone, rubber and other conformable materials.

A valve assembly, in turn, may be disposed within the valve cup (94).The valve assembly provides for retention of product within the aerosoldispenser until the product is selectively dispensed by a user. Thevalve assembly may be selectively actuated by an actuator. A nozzle andrelated valve assembly components may optionally be included, dependingupon the desired dispensing and spray characteristics. The valveassembly may be attached using conventional and known means. The valveassembly and actuator may be conventional and do not form part of theclaimed invention.

Selective actuation of the valve assembly allows the user to dispense adesired quantity of the product on demand. Any number of known valveassemblies may be usable with the present invention, with a valve madeaccording to commonly assigned U.S. Pat. No. 9,132,955 being suitable. Asuitable plug and sleeve type valve assembly may be made according tothe teachings of commonly assigned U.S. Pat. No. 8,511,522.

The aerosol dispenser, and components thereof, may have a longitudinalaxis, and may optionally be axi-symmetric with a constant round crosssection. Alternatively, the outer container (80), collapsible bag (92),etc., may be eccentric and/or may have a square, elliptical or otherconstant or variable cross section.

The outer container (80) may comprise a plastic pressurizeablecontainer. The plastic may be polymeric, and particularly comprise PET.The valve assembly, and optional valve cup (94) may be joined to theneck (84) of the outer container (80) in known fashion.

The pressurizeable container may further include a propellant. Thepropellant may comprise nitrogen, air and mixtures thereof. Propellantlisted in the US Federal Register 49 CFR 1.73.115, Class 2, Division 2.1and 2.2 are also considered acceptable. The propellant may particularlycomprise a Trans-1,3,3,3-tetrafluoroprop-1-ene, and optionally a CASnumber 1645-83-6 gas. One such propellant is commercially available fromHoneywell International of Morristown, N.J. under the trade nameHFO-1234ze or SOLSTICE.

If desired, the outer container (80), valve cup (94), valve assembly,and/or piston may be polymeric. By polymeric it is meant that thecomponent is formed of a material which is plastic, comprises polymers,and/or particularly polyolefin, polyester or nylons, and moreparticularly PET. Thus, the entire aerosol dispenser or, specificcomponents thereof, may be free of metal, allowing microwaving.Microwave heating of the aerosol dispenser or pressurizable containertherefor provides for heating of the product prior to dispensing.Heating of the product prior to dispensing may be desirable if theproduct is applied to the skin, becomes more efficacious at lowerviscosities, or is to be eaten.

The outer container (80), and all other components, except the TPE seal,may comprise, consist essentially of or consist of PET, PEN, Nylon, EVOHor blends thereof to meet DOT SP 14223. Such materials may be selectedfrom a single class of recyclable materials, as set forth above by theSPI and as described in commonly assigned U.S. Pat. No. 9,296,550.

The valve cup (94) may have a valve cup (94) periphery complementary tothe neck (84) periphery. At least one of the valve cup (94) and/orcontainer neck (84) may have one or more channels (47) therethrough.Additionally or alternatively, the channels (47) may be formed at theinterface between the valve cup (94) and container neck (84).Particularly, the bottom edge of the upper container portion and topedge of the lower container portion are complementary to the other. Thechannels (47) may be formed by irregularities, such as crenulations,merlins, serrations, notches (38), teeth, etc. between and on the bottomedge of the upper container portion and/or top edge of the lowercontainer portion.

In manufacture, after the inner and outer preforms (30) are blow moldedinto a functionable dispenser, a manifold may supply propellant, underpressure, through at least one channel between the upper containerportion and lower container portion. The manifold may be retractinglydisposed above the outer container (80). The manifold may be broughtinto contact with the valve cup (94), forming a temporary sealtherebetween. Suitable channels (47) are particularly described incommonly assigned U.S. Pat. No. 8,869,842 to Smith at FIG. 8, column 7,lines 57 to column 8, line 2 and column 8, lines 44-60.

While the temporary seal is established between the manifold and valvecup (94), the propellant may be charged into the upper container portionand/or lower container portion. A suitable process for charging theouter container (80) with propellant is described in commonly assignedU.S. Pat. No. 8,869,842 to Smith at FIG. 9 and column 8, lines 15-35.

At 21 degrees C., the outer container (80) may be pressurized to aninternal gage pressure of 100 to 1300, 110 to 490 or 270 to 420 kPa. Aparticular aerosol dispenser may have an initial propellant pressure of1100 kPA and a final propellant pressure of 120 kPa, an initialpropellant pressure of 900 kPA and a final propellant pressure of 300kPa, an initial propellant pressure of 500 kPA and a final propellantpressure of 0 kPa, etc.

If desired, the propellant 40 may be condensable. Generally, the highestpressure occurs after the aerosol dispenser 20 is charged with product42 but before the first dispensing of that product 42 by the user. Acondensable propellant 40, when condensed, provides the benefit of aflatter depressurization curve at the vapor pressure, as product 42 isdepleted during usage. A condensable propellant 40 also provides thebenefit that a greater volume of gas may be placed into the container ata given pressure. A condensable propellant 40, such as HFO-1234ze, maybe charged to a gage pressure of 100-400 kPa at 21 degrees C.

One of skill will recognize the plural preform assembly (20) of theinvention may be used with trigger pump sprayers or finger pumpsprayers, if an aerosol container is not desired. In a variantembodiment, a non-aerosol system using an elastically deformable bandmay be used, as described in commonly assigned U.S. Pat. No. 8,631,970.

Combinations

A. A plural preform assembly (20) for a container, said plural preformassembly (20) having a longitudinal axis defining a longitudinaldirection, said plural preform assembly (20) comprising:

an outer preform (30) having an outer preform (30) open end and an outerpreform (30) closed end longitudinally opposed thereto, an outer preform(30) sidewall joining said outer preform (30) open end and said outercontainer (80) closed end, said outer preform (30) having an outerpreform (30) inner surface and an outer preform (30) outer surface, andan inner preform (40) disposed in said outer preform (30), said innerpreform (40) having an inner preform (40) open end and an inner preform(40) closed end longitudinally opposed thereto, an inner preform (40)sidewall joining said inner preform (40) open end and said inner preform(40) closed end, said inner preform (40) having an inner preform (40)inner surface and an inner preform (40) outer surface,

said inner preform (40) and said outer preform (30) being mechanicallyjoined at said respective open ends by a radial interference fit.

B. A plural preform assembly (20) for an aerosol container, said pluralpreform assembly (20) having a longitudinal axis defining a longitudinaldirection, said plural preform assembly (20) comprising: an outerpreform (30) having an outer preform (30) open end and an outer preform(30) closed end longitudinally opposed thereto, an outer preform (30)sidewall joining said outer preform (30) open end and said outer preform(30) closed end, said outer preform (30) having an outer preform (30)inner surface and an outer preform (30) outer surface, and

an inner preform (40) disposed in said outer container (80), said innerpreform (40) having an inner preform (40) open end and an inner preform(40) closed end longitudinally opposed thereto, an inner preform (40)sidewall joining said inner preform (40) open end and said inner preform(40) closed end, said inner preform (40) having an inner preform (40)inner surface and an inner preform (40) outer surface,

said inner preform (40) and said outer preform (30) being mechanicallyjoinable at said respective necks (84) by a radial interference fit, andnot touching the other at said respective sidewalls or respective closedends,

said inner preform (40) and said outer preform (30) being moldable toform an aerosol dispenser having a bag (92) therein.

C. A method of making a bag (92) in bottle assembly (20), said methodcomprising the steps of:

-   -   a. providing a plural preform assembly (20) for container, said        plural preform assembly (20) having a longitudinal axis defining        a longitudinal direction, said plural preform assembly (20)        having an outer preform (30) having an outer preform (30) open        end and an outer preform (30) closed end longitudinally opposed        thereto, an outer preform (30) sidewall joining said outer        preform (30) open end and said outer preform (30) closed end,        said outer preform (30) having an outer preform (30) inner        surface and an outer preform (30) outer surface, and an inner        preform (40) disposed in said outer container (80), said inner        preform (40) having an inner preform (40) open neck (84) and an        inner preform (40) closed end longitudinally opposed thereto, an        inner preform (40) sidewall joining said inner preform (40) open        end and said inner preform (40) closed end, said inner preform        (40) having an inner preform (40) inner surface and an inner        preform (40) outer surface, said inner preform (40) and said        outer preform (30) being joined together by an interference fit,    -   b. blowmolding said plural preform assembly (20) while said        inner preform (40) is substantially disposed in said outer        preform (30) to form a bag (92) in bottle assembly (20) having a        collapsible blown bag (92) within an outer container (80), and    -   c. permanently joining said collapsible blown bag (92) and said        outer container (80) at said respective neck (84),        -   wherein said steps a, b and c are performed in sequence.

D. A plural preform assembly (20) for a container according toparagraphs A or B further comprising an intermediate preform (96)disposed between said inner preform (40) and said outer preform (30).

E. A plural preform assembly (20) for a container according to paragraphD further comprising circumferentially spaced apart ribs (48) disposedon said inner preform (40) and extending radially outwardly to contactsaid outer preform (30) inner surface and provide an interference fitbetween said inner preform (40) and said outer preform (30).

F. A plural preform assembly (20) for a container according toparagraphs A, B, D and E further comprising circumferentially spacedapart ribs (48) disposed on said outer preform (30) and extendingradially inwardly to contact said inner preform (40) outer surface andprovide an interference fit between said inner preform (40) and saidouter preform (30).

G. A plural preform assembly (20) according to paragraphs E and Fcomprising 10 to 24 equally circumferentially spaced ribs (48).

H. A plural preform assembly (20) according to paragraphs E and Fcomprising 4 to 10 equally circumferentially spaced ribs (48).

I. A plural preform assembly (20) according to paragraphs E, F, G and Hwherein at least a portion of said ribs (48) extends radially outwardlya distance of 4 to 6 mm.

J. A plural preform assembly (20) according to paragraphs E, F, G, H andI wherein said ribs (48) taper inwardly toward said bottom of saidpreform.

K. A plural preform assembly (20) according to paragraphs A, B, D, E, Fand G comprising a first plurality of ribs (48) and second plurality ofribs (48) on one of said inner preform (40) and said outer preform (30),each of said ribs (48) of said first plurality and said second pluralityradially extending towards the other preform, said ribs (48) of saidfirst plurality radially extending a greater distance than said ribs(48) of said second plurality.

L. A plural preform assembly (20) according to paragraphs E, H, I, J,and K further comprising circumferentially spaced apart notches (38)disposed on said outer preform (30) and being complementary to said ribs(48) of said inner preform (40) whereby said ribs (48) can engage saidnotches (38) when said inner preform (40) and said outer preform (30)are nested.

M. A plural preform assembly (20) according to paragraphs A, B, D, G, H,I, J, K and L further comprising ribs (48) on one of said inner preform(40) and said outer preform (30), said ribs (48) radially extendingtowards the other, and further comprising complementary notches (38) onthe other of said outer preform (30) and said inner preform (40), saidribs (48) intercepting said notches (38) when said inner preform (40)and said outer preform (30) are removably joined together.

N. A plural preform assembly (20) according to paragraphs L and Mcomprising an equal number of ribs (48) and notches (38).

O. A plural preform assembly (20) according to paragraphs A, B, D, G, H,I, J, K, L, M, N wherein said inner preform (40) further comprises anoutwardly extending collar juxtaposed with said inner preform (40) openneck (84) and further comprising circumferentially spaced apart ribs(48) extending outwards from said inner preform (40) outer surface, atleast a portion of said ribs (48) intercepting said collar.

P. A plural preform assembly (20) according to paragraph O wherein saidribs (48) have a free end longitudinally distal from said collar, saidribs (48) subtending a collar diameter at said collar and a free enddiameter at a free ends, said collar diameter being greater than saidfree end diameter.

Q. A plural preform assembly (20) according to paragraphs A, B, D, G, H,I, J, K, L, M, N, O and P comprising ribs (48) both on said innerpreform (40) radially extending outwardly towards said outer preform(30) and comprising ribs (48) on said outer preform (30) radiallyextending towards said inner preform (40).

R. A method according to paragraph C wherein said inner preform (40) andsaid outer preform (30) are removably joined together during steps a andb.

S. A method according to paragraphs C and R further comprising the stepof permanently joining said inner preform (40) and said outer preform(30) after step c is preformed.

T. A method according to paragraphs C, R and S further comprising thestep of charging said outer container (80) with propellant afterperforming step b and before step c.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm” and a pressure disclosed as “about 1100 kPa” is intendedto include 1103.2 kPa.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern. All limits shown herein as defining a range may be used with anyother limit defining a range. That is the upper limit of one range maybe used with the lower limit of another range, and vice versa.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of making a bag in bottle assembly, themethod comprising the steps of: providing a plural preform assembly forcontainer, the plural preform assembly having a longitudinal axisdefining a longitudinal direction, the plural preform assembly having anouter preform having an outer preform open end and an outer preformclosed end longitudinally opposed thereto, an outer preform sidewalljoining the outer preform open end and the outer preform closed end, theouter preform having an outer preform inner surface and an outer preformouter surface, and an inner preform having an inner preform open end andan inner preform closed end longitudinally opposed thereto, an innerpreform sidewall joining the inner preform open end and the innerpreform closed end, the inner preform having an inner preform innersurface and an inner preform outer surface, the inner preform and theouter preform being removably joined together, wherein a gap is presentbetween the inner preform closed end and the outer preform closed endand between the outer preform inner surface and the inner preform outersurface; blowmolding the plural preform assembly while the inner preformis substantially disposed in the outer preform, wherein the innerpreform is blown to form a collapsible blown bag and the outer preformis blown to form an outer container, and wherein the collapsible blownbag and the outer container to form a bag in bottle assembly; andpermanently joining a portion of the collapsible blown bag and a portionof the outer container; wherein the plural preform assembly comprisescircumferentially spaced apart ribs disposed on the inner preform andextending radially outwardly to contact the outer preform inner surfaceand provide a friction fit between the inner preform and the outerpreform.
 2. The method of claim 1, wherein the inner preform and theouter preform are joined together by a friction fit.
 3. The method ofclaim 1, wherein the plural preform assembly comprises an intermediatepreform disposed between the inner preform and the outer preform.
 4. Themethod of claim 1, wherein the plural preform assembly comprisescircumferentially spaced apart ribs disposed on the outer preform andextending radially inwardly to contact the inner preform outer surfaceand provide a friction fit between the inner preform and the outerpreform.
 5. The method of claim 1, wherein the plural preform assemblycomprises a first plurality and second plurality of ribs on one of theinner preform and the outer preform, each of the ribs of the firstplurality and the second plurality radially extending towards the otherpreform, the ribs of the first plurality radially extending a greaterdistance than the ribs of the second plurality.
 6. The method of claim1, wherein the inner preform of the plural preform assembly comprises anoutwardly extending collar juxtaposed with the inner preform open endand wherein the circumferentially spaced apart ribs extending outwardsfrom the inner preform outer surface intercept the collar.
 7. The methodof claim 1, wherein the inner preform and the outer preform areremovably joined prior to blow molding.
 8. The method of claim 1,comprising charging the outer container with propellant.
 9. A method ofmaking a bag in bottle assembly, the method comprising the steps of:providing a plural preform assembly for container, the plural preformassembly having a longitudinal axis defining a longitudinal direction,the plural preform assembly having an outer preform having an outerpreform open end and an outer preform closed end longitudinally opposedthereto, an outer preform sidewall joining the outer preform open endand the outer preform closed end, the outer preform having an outerpreform inner surface and an outer preform outer surface, and an innerpreform having an inner preform open end and an inner preform closed endlongitudinally opposed thereto, an inner preform sidewall joining theinner preform open end and the inner preform closed end, the innerpreform having an inner preform inner surface and an inner preform outersurface, the inner preform and the outer preform being removably joinedtogether, wherein a gap is present between at least one of the innerpreform closed end and the outer preform closed end and the outerpreform inner surface and the inner preform outer surface; blowmoldingthe plural preform assembly while the inner preform is substantiallydisposed in the outer preform to form a bag in bottle assembly includinga collapsible blown bag within an outer container, wherein thecollapsible blown bag is blown from the inner preform and the outercontainer is blown from the outer preform, and wherein the collapsibleblown bag has an open neck portion and the outer container has an openneck portion; and permanently joining the collapsible blown bag and theouter container at the open neck portion of the collapsible blown bagand the open neck portion of the outer container; wherein the pluralpreform assembly comprises circumferentially spaced apart ribs disposedon the inner preform and extending radially outwardly to contact theouter preform inner surface and provide a friction fit between the innerpreform and the outer preform.
 10. The method of claim 9, wherein theinner preform and the outer preform are joined together by a frictionfit.
 11. The method of claim 9, wherein the plural preform assemblycomprises an intermediate preform disposed between the inner preform andthe outer preform.
 12. The method of claim 9, wherein the plural preformassembly comprises circumferentially spaced apart ribs disposed on theouter preform and extending radially inwardly to contact the innerpreform outer surface and provide a friction fit between the innerpreform and the outer preform.
 13. A method of making a bag in bottleassembly, the method comprising the steps of: providing a plural preformassembly for container, the plural preform assembly having an outerpreform having an outer preform open end and an outer preform closed endlongitudinally opposed thereto, an outer preform sidewall joining theouter preform open end and the outer preform closed end, and an innerpreform having an inner preform open end and an inner preform closed endlongitudinally opposed thereto, an inner preform sidewall joining theinner preform open end and the inner preform closed end, the innerpreform having an inner preform inner surface and an inner preform outersurface, the inner preform and the outer preform being removably joinedtogether, wherein the plural preform assembly comprisescircumferentially spaced apart ribs disposed between the inner preformand the outer preform and extending radially between the inner preformand the outer preform such that the ribs contact a portion of at leastone of the outer preform and the inner preform; blowmolding the pluralpreform assembly while the inner preform is substantially disposed inthe outer preform, wherein the inner preform is blown into a bag and theouter preform is blown into an outer container, and wherein the bag hasa neck portion and the outer container has a neck portion; andpermanently joining the neck portion of the bag and the neck portion ofthe outer container.
 14. The method of claim 13, wherein the innerpreform and the outer preform are joined together by a friction fit. 15.The method of claim 13, wherein the plural preform assembly comprises anintermediate preform disposed between the inner preform and the outerpreform.
 16. The method of claim 13, wherein the inner preform and theouter preform are removably joined prior to blow molding.
 17. The methodof claim 13, comprising charging the outer container with propellant.